Zuri™ Installation Guidelines

Zuri™ Installation Guidelines
Before installing any decking materials or stairway materials, review the following
guidelines and installation instructions for proper installation procedure. Zuri™ Decking
has similar behavior to wood and composite decking; therefore, similar installation
techniques should be used. In order to avoid improper installation, additional techniques,
recommendations, and guidelines have been provided below. Following the provided
instructions while using the same good building principals used in wood and composite
decking installation will result in a correct Zuri™ Decking installation.
Although Zuri™ Decking is similar to wood and composite decking, it may not be
appropriate for every application. Royal Building Products cannot be held liable for
improper installation of Zuri™ Decking. All deck structural framing should be built in
accordance with local building codes. Many municipalities require decks to be designed by
a local architect or engineer. It is recommended that you consult your local building code
compliance office for any requirements. If you have any questions or need further
assistance, please call (800) 488-5245 or visit http://www.royalbuildingproducts.com.
What Is Zuri Decking? – Trivance™ A new & unique Technology that combines
Cellular PVC, Photorealistic Print, and Premium Acrylic to create a deck board like no
other. A few key points:
o
No resealing, staining or painting required
o
Scratch resistant
o
Fade resistant
o
Moisture resistant
o
Stain resistant
o
Slip Resistant
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Zuri™ Installation Guidelines
STORAGE & HANDLING
Material Storage
Zuri – has been properly packaged from the manufacturer and should be stored and
transported in this packaging until installation. The packaging also includes the arranging
of the grain patterns to ensure pattern variation during the install, so the installer should
work from one unit at a time and remove boards as illustrated below.
Leave protective wrapping on decking material throughout the installation to avoid damage, protect from
construction debris, and maintain a consistent board temperature.
Store decking material on a flat surface to avoid bowing or warping (adjusting support blocks may be
required on uneven ground).
Use protective corner clips when banding to prevent stress damage to the decking material.
Do not store in heat exceeding 120 °f.
Material Handling
Although Zuri has been developed with the Trivance™ Technology and has durable low
maintenance features, special care is requested when handling these boards to minimize
scuffs, nicks and to preserve the beauty of the finish. Think of the product as a
prefinished wood in perspective to handling. A few key guidelines when moving and
working with Zuri:
NEVER dump Zuri prepackaged products when unloading.
When carrying product, use two people and stand board on its edge for better support.
Avoid sliding the back of the product (Tan substrate) against the face (Clear protective coat) during the
moving or working of the material. When removing product from packaging lift the board as opposed to
sliding on it edge.
Avoid sliding or dragging tools and equipment during the construction process.
Keep the work area clean and free from scarp or construction debris.
After installation, protect deck from masonry dust, sheet rock dust, and other typical construction debris
Zuri Deck grain patterns have been blended on the pallet from the factory, therefore
the material should be removed from the pallet horizontally (side to side) to ensure
grain pattern variation throughout the build
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Zuri™ Installation Guidelines
Tools & Equipment
Safety
As with all construction projects the proper safety equipment should be utilized at
all times IE Safety Glasses, hearing protection, Gloves, etc. Dust mask and long sleeves
may be used if you are cutting in confined areas. Safe lifting practices should also be used
when handling product as the weight and flex of the product can be awkward.
Tools
Zuri – has been created to have a finish comparable to that of interior hardwood
flooring, with a durability and toughness to withstand the hash outdoor elements.
Therefore special attention is required when cutting and working with the product, the
mind set should mimic that of working with any prefinished material. For this reason the
tools required may be outside the scope of a conventional deck contractor and more in the
realm of a finish carpenter. A list of tools:
Saws & Blades:
10” or 12” Miter Saw – Used for finished end-cuts and Trim miters
o Minimum Blade requirements – Carbide 60 to 80 tooth
o Blade recommendation – CMT 96 tooth fine finish (12”
Jig Saw – used for cutting notches around obstacles, protrusions IE Posts, columns
o Minimum Blade requirements – 10 TPI
o Blade recommendation – 10 TPI with board positioned Face Down
Circular Saw or Portable Table saw – Used for ripping deck boards.
o Minimum Blade requirements – Carbide Tooth – 24 T (7 ¼”Blade) & 60T (10” blade)
o Blade recommendation – (71/4”) 60 T Skilsaw Carbide finishing (10”) CMT 80 T Fine finish
Work Station:
It is recommended to use a Miter saw stand, roller
stands, or out feed tables when cutting Zuri decking
and Zuri deck trims. The objective is to support the
material during the cutting process.
Drill & Drivers
Drills and Drill bits as well as impact drivers and
appropriate driver tips are required.
Layout Tools
Typical tools required such as tape, chalk line,
straight edge, etc
Plate Joiner – used for the EB-TY™ Fastener
application
CAMO™ Marksmen Pro ™NB – tool provided with
the Camo™ hidden fastening system
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Zuri™ Installation Guidelines
Design & Layout
Design Principles
Due to the diversity of installation scenarios it is the installer’s responsibility to
determine the specific requirements for each application. Royal recommends that an
architect, engineer or local building official review Zuri applications prior to install. The
intent of the instructions is to set forth principles, work parameters, and provide a working
knowledge of Zuri’s characteristics.
Expansion / Contraction:
Expansion and Contraction are most significant where extreme temperature change exists. All PVC
moves with temperature change and it moves differently from wood decking products. Wood will typically
expand and contract in the width direction and Zuri will move in its length. Moisture has the biggest impact
on Wood and no effect on Zuri’s PVC substrate. The key to a successful build is planning for this lengthwise
movement. A few ways to control movement are:
Fasten Boards within 1/2” of the ends.
Butt joints must be tight (above 32°f – below leave 1/16” gap)
Minimum of ¼” space between Zuri boards and any structure, post or obstruction.
Upon cutting board to finished length, install as soon as possible
On long decks (20’ and greater) the board orientation to run boards in the narrow direction. For example
– on a 40’ X 10’ build install 10’ boards perpendicular instead of 20’ boards parallel to the structure.
Zuri trims
Zuri Trim is designed as part of our Decking Solution and is required on all builds were the deck board
ends would otherwise be exposed. The trim is designed to protect the ends of boards, provide transition
solution and overall aesthetic. Best practices are:
PVC Glue all miter joints
Do not glue Butt Joints (to create an expansion joint)
Face screw (HEADCOTE CAP-TOR Stainless Steel Deck Screws) only on the vertical side – use hidden
fastener on the horizontal surface.
Use a supporting block when cutting on Miter saw to ensure proper angle
Zuri Coated Ends
Zuri requires all visible ends to be coated to conceal the lighter colored substrate. This is purely
cosmetic, but it is required from an aesthetic perspective. Coating should be applied after cutting and prior
to the installation of all boards. The coating colors are:
Weathered Gray –
Sherwin Williams –
2840 Hammered Silver
Pecan Sherwin Williams –
1112 Setter’s Coat
Walnut Sherwin Williams –
1112 Setter’s Coat
Brazilia Sherwin Williams –
6062 Rugged Brown
Chestnut Sherwin Williams –
6117 Smokey Topaz
Zuri Pattern variation
Zuri provides six (6) different grain patterns. The product is packaged to aid in pattern variation, but
installer must be mindful throughout the build to make certain pattern variation is maintained.
Rooftop & Patio Decks:
Zuri is a suitable and logical product for rooftop & patios (sunken framing) as long as the following
principles are applied to the substructure (framing):
Must be soundly attached to the roof or patio (no floating framing)
Minimum Joist height of 3-½”
Must be vented to allow heat to escape (ambient air should not exceed 160°f )
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Zuri™ Installation Guidelines
Design & Layout
Layouts
The layout or board orientation can have a big impact on the finished products
appearance and perceived performance. Points of consideration:
Staggered butt-joints - On runs exceeding 20’ or unique builds have need of butt-joints, additional
farming is required to help control movement. Blocking or “Sistering” on each side of all Butt Joints is
mandatory. The blocking must be screwed to mating frame tightly.
Feature board / Breaker board – This concept will disguise movement the best. By strategically placing
a board perpendicular to the main build direction will simulate shorter runs and the perpendicular board
moves very little in the width axis resulting in half the gap size of conventional joint
Inlays, boarders and medallions – This concept, like the feature board, will aid in canceling the
movement of the Zuri. It is imperative that the framing is altered to accommodate design. The Zuri can not
be cantilevered more than one inch.
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Zuri™ Installation Guidelines
Framing
Framing
Building codes and/or officials should be consulted prior to Zuri installation to confirm
structure conforms to local requirements. Zuri is load bearing, but should never be used for
structural framing. The quality of the framing will directly impact the overall appearance of
the Zuri decking as Zuri will conform to the shape of any uneven framing.
We suggest framing with KDAT (kiln dried after treatment) framing lumber. This wood is usually lighter,
straighter and will not expand or contract as much during construction.
Joist system must be level and flush
Install all railing posts of post supports prior to Zuri install. Railing supports must NOT be attached to
Zuri Decking.
Joist Spacing:
Cellular PVC is not as rigid or stiff as traditional hardwoods; Zuri boards are code approved for a 16” oncenter installation. If a springy or cushioned feel is a concern, 12” on-center construction is recommend.
24” on-center is unacceptable for Zuri.
16” On-center – is permissible for
standard residential applications. This
only applies if boards are installed
perpendicular to joists.
12” on-center – is required for high
traffic areas, commercial builds and
installs using a 45° or herringbone
layout.
12” on-center – is required for all step
stringers.
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Zuri™ Installation Guidelines
Fasteners
Hidden fasteners
Zuri is different form conventional wood, composite and other PVC decking products.
The Trivance structure of Zuri requires face screws be kept to a minimum. All face screws
on the horizontal plan ought to be placed in an inconspicuous location, namely against a
structure, under trimmed areas, under handrails etc. Face Screws on the vertical plan,
such as Zuri Trims, Risers of Fascia applications are acceptable. We have approved the
following Hidden fastening Systems for installing Zuri:
Camo™Marksman Pro - Gap size of 3/16”
Please follow the Camo™ installation instructions provided with
the system. This method is a Toe-Screw application with the
following attributes:
Least expensive
Fast
Top performer in respect to restricting expansion / contraction
movement
Product design is very conducive to board replacement
EB-TY™ Original Series Hidden Deck fastening
system - Gap size of 3/32”
This system requires a plate joiner or router to cut slot in Zuri
decking to accommodate a “Biscuit” shaped retainer that screwed
through the board into the framing. EB-TY will provide complete
instructions with product, but an overview technique and key
features are:
Smallest gap size available
Performed well in respect to restricting expansion / contraction
movement.
Requires 1 fastener per sq/ft of decking.
Headcote Cap-Tor - #10 x 2-1/2" Screws
Use to face-screw Zuri Trim. NOTE: 305 stainless for inland
builds and 316 Stainless for seaside or brackish water applications
Approved for use with ACQ treated lumber.
Available in color matched coating.
o Weathered Gray – Tan Gray
#31
o Pecan Cedar
#81
o Walnut Brown
#34
o Brazilia Mahogany
#82
o Chestnut –
Buckskin
#63
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Zuri™ Installation Guidelines
Installation Process
Installation progression
Zuri must be installed in the following sequence. This section will be divided in order of
installation:
1.
2.
3.
4.
Fascia / Skirt Board – Main body of build (DO NOT Clad stair risers at this point)
Zuri Trim
Main Body decking
Steps and Landings
Step 1 – Fascia / Skirt board
All fascias should be installed prior to decking. We suggest using Royal’s S4S trim
products with Cortex™ style fasteners. Full installation
instructions for this application are available at
www.royalbuildingproducts.com. A few application specific
guidelines are:
Fascia must fully cover framing, as it will support the Zuri Trim
All miter Joint are to be Glued – PVC Cement
Expansion joint are required on runs exceeding 20’ – shiplap joint is
recommended
Required Fastening schedule for PVC Trim
o Boards 6” wide or less –
2 fasteners, 16” on center
o Boards 8”to 10” wide–
3 fasteners, 16” on center
o Boards 12” wide or more –
4to5 fasteners, 16” on center
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Zuri Installation Guidelines
Installation Process
Step 2 – Zuri Trim
Install Zuri Trim around the entire perimeter of the deck body. Do not trim steps at
this time. The trim must be installed with a combination of face screws and one of the
approved fastening systems. They follow techniques should be followed:
Maintain straight lines and square corners as this will be starter for
decking.
o Use chalk line, string, or straight edge to ensure alignment
o Use framing square, 3,4,5 method or cross measure to
maintain square.
Secure face with Headcote Cap-Tor - #10 x 2-1/2" Screws and
hidden fastener on backside. See options
All miter joints must be glued (PVC Cement)
All miter joints must have an expansion joint within 6’ to allow for
movement.
Paint all butt-ends on expansion joints (NO glue)
Glue all miter-joints (NO Paint)
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Zuri Installation Guidelines
Installation Process
Step 3 – Zuri Main Body decking
Install Zuri deck boards with one of the two approved fastening methods. Work from
the trim side or highest traffic area toward the structure or lest traffic area. Remember to
monitor the grain patterns to guarantee grain variation. Feature boards, transition board
and/or inlay work should be installed first, and then the main body, this allows for more
precise cutting.
Follow the selected fastening systems instructions.
o Camo provides 3/16” gap spacing
o Eb-Ty provides 3/32” & 1/8” gap spacing
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Zuri Installation Guidelines
Installation Process
Step 4 – Steps
Zuri step installation is a bit different than conventional methods and requires the
same attention to the installation sequence as the main deck. The following progression
will be the order of install and each process must be completed before moving next. This
section only covers the Decking / Fascia applications and presumes framing is complete.
1. Mount the fascia on the stringers and
first riser.
Follow same guidelines
listed in the Fascia /
Skirt Board section.
NOTE: Notch the
stringer to
accommodate the trims
2. Attach Decking
Boards.
Use the EB-TY system for all stair application.
Dry fit trim and full deck board to calculate the width of the ripped board (using EB-TY™ as
spacer)
Face-screw the back of
the ripped boards
within ¾” of the ripped
edge. (screws will be
covered by risers)
3. Attach Risers and Zuri Trim.
Install the remaining risers
Cut and pre-assemble the Trims for each step.
Install the assembled trims as directed in the Trims section
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Zuri Installation Guidelines
Tips & Techniques
Gluing Zuri™- Zuri’s PVC substrate can be chemically welded with PVC Glue. This bond is recommended on
all miters and filler board applications. Best practices are:
Use PVC Cement in conjunction with Loctite Super Glue (locations identified below) to speed the
process and eliminate the need for clamping.
o Oatey – Heavy Duty – Clear PVC
Cement
o Loctite – Exterior rated – Superglue
Per-glue joint before installing
Filler Boards (boards less than 5.5” wide) may be
required if ripped edge is not against a structure or in a high traffic area.
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